Method for building and using three-dimensional objects containing embedded identification-tag inserts

ABSTRACT

A method for building a three-dimensional object containing an identification-tag insert, the method comprising performing a build operation to form layers of the three-dimensional object using a layer-based additive technique, placing the identification-tag insert on at least a portion of the layers during the build operation, and reading information from the identification-tag insert.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation of U.S. patent application Ser. No.12/006,956, filed 1 Jan. 8, 2008, and published as U.S. Pat. No.8,858,856; the contents of which are incorporated by reference in itsentirety.

BACKGROUND

The present invention relates to methods for building three-dimensional(3D) objects. In particular, the present invention relates to methodsfor building 3D objects with layer-based additive techniques.

Rapid prototyping/rapid manufacturing (RP/RM) systems are used to build3D objects from computer-aided design (CAD) models using one or morelayer-based additive techniques. Examples of commercially availablelayer-based additive techniques include fused deposition modeling, inkjetting, selective laser sintering, electron-beam melting, andstereolithographic processes. For each of these techniques, the CADmodel of the 3D object is initially sliced into multiple horizontallayers. For each sliced layer, a build path is then generated, whichprovides instructions for the particular RP/RM system to form the givenlayer. For deposition-based systems (e.g., fused deposition modeling andink jetting), the build path defines the pattern for depositing roads ofbuild material from a moveable deposition head to form the given layer.Alternatively, for energy-application systems (e.g., selective lasersintering, electron-beam melting, and stereolithographic processes), thebuild path defines the pattern for emitting energy from a moveableenergy source (e.g., a laser) to form the given layer.

In fabricating 3D objects by depositing layers of build materials,supporting layers or structures are typically built underneathoverhanging portions or in cavities of objects under construction, whichare not supported by the build material itself. A support structure maybe built utilizing the same deposition techniques by which the buildmaterial is deposited. The host computer generates additional geometryacting as a support structure for the overhanging or free-space segmentsof the 3D object being formed. The support material adheres to the buildmaterial during fabrication, and is removable from the completed 3Dobject when the build process is complete.

While fabricating 3D objects with layer-based additive techniques, acommon issue for manufacturers is the identification and tracking of the3D objects during post-build operations. This is particularly true forrapid manufacturing applications, where multiple RP/RM systemscontinuously build 3D objects based on large-volume job queues. In thesecases, it may be difficult to identify and track the large quantities of3D object built, particularly when such 3D objects typically requirepost-build operations before completion. Thus, there is an ongoing needfor methods for identifying and tracking 3D objects during fabricationprocesses with layer-based additive techniques.

SUMMARY

The present invention relates to a method for building a 3D objectcontaining an identification-tag (ID-tag) insert. The method includesperforming a build operation to form layers of the 3D object using alayer-based additive technique, and placing the ID-tag insert on atleast a portion of the layers during the build operation, thereby atleast partially embedding the ID-tag insert in the 3D object. The methodfurther includes reading information from the ID-tag insert.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow diagram of a method for building a 3D object containingan ID-tag insert.

FIGS. 2A-2C are schematic views of a first 3D object being built using ahorizontal placement technique for placing an ID-tag insert in the first3D object.

FIGS. 3A-3C are schematic views of a second 3D object being built usinga vertical placement technique for placing an ID-tag insert in thesecond 3D object.

FIGS. 4A-4C are schematic views of a third 3D object being built using anear-vertical placement technique for placing an ID-tag insert in thethird 3D object.

FIG. 5 is a top perspective view of a fourth 3D object, whichillustrates a bent-vertical placement technique for placing an ID-taginsert in the fourth 3D object.

FIG. 6 is a bottom perspective view of a fifth 3D object, whichillustrates the use of a break-away ID-tag insert.

DETAILED DESCRIPTION

FIG. 1 is a flow diagram of method 10 for building a 3D object with anRP/RM system using a layer-based additive technique, where the 3D objectcontains an ID-tag insert that provides information relating to the 3Dobject and/or relating to one or more actions to perform on the 3Dobject. Method 10 includes steps 12-26, and initially involves receivinga CAD model of the 3D object to be built (step 12). The CAD model isdesirably received by a host computer of the RP/RM system, and includesa data representation of the 3D object in a data format compatible withthe RP/RM system (e.g., STL-format data files).

The host computer then generates a data representation of the ID-taginsert in the received CAD model (step 14), where the datarepresentation of the ID-tag insert dimensionally corresponds to aphysical ID-tag insert that will be placed in the 3D object during abuild operation with the RP/RM system. The ID-tag insert may be any typeof receiver-transmitter component that is compatible with thelayer-based additive technique used, and that is capable of transmittinga reply signal when electronically interrogated. Examples of suitableID-tag inserts for use with method 10 include active and passiveradio-frequency identification (RFID) tags, such as high-frequency RFIDtags and ultra high-frequency RFID tags. Examples of particularlysuitable ID-tag inserts for use with method 10 include passive RFIDtags, which may be provided as pill-form ID tags (e.g., glass-pill tags)and thin-film ID tags. In one embodiment, the layers of the 3D objectfunctions as the substrate for the ID-tag insert. In this embodiment,the ID-tag insert may merely include the electronic components (e.g.,the integrated circuit and antenna), which are placed on the layers ofthe 3D object during the build operation.

Suitable thin-film ID-tag inserts desirably have average filmthicknesses that are about equal to the thickness of a single layer ofthe 3D object, or that are about equal to the combined thicknesses ofmultiple layers of the 3D object (e.g., less than about 500micrometers). This allows the ID-tag insert to be substantially flushwith the layers of the 3D object, thereby providing a substantiallyplanar working surface for building subsequent layers of the 3D object.Examples of suitable average film thicknesses for the thin-film ID-taginserts range from about the thickness of a single layer to about thecombined thickness of 20 layers, with particularly suitable thicknessesfor the thin-film ID-tag inserts ranging from about the thickness of asingle layer to about the combined thickness of 10 layers, and with evenmore particularly suitable thicknesses for the thin-film ID-tag insertsranging from about the thickness of a single layer to about the combinedthickness of 5 layers.

As used herein, the term “substantially flush” refers to arrangementswhere the surfaces are flush (i.e., coplanar) or where the top surfaceof the ID-tag insert is slightly below the top layer of the build layersalong a vertical z-axis. Layer-based additive processes of RP/RM systemsare capable of making up the differences for vertical offsets that arewithin a few layers below the top layer of the build layers.Accordingly, suitable vertical offsets between the top surfaces of theinserts and the top layers of the build layers include thicknessesranging from coplanar surfaces to distances of about three layers, withparticularly suitable vertical offsets ranging from coplanar surfaces todistances of about one layer, where the non-coplanar distances of thetop surfaces of the inserts extend below the top layers of the buildlayers along the vertical z-axis.

As discussed below, the ID-tag insert may include a variety ofinformation, such as instructions for handling the 3D object after thebuild operation with the RP/RM system is complete (e.g., identificationinformation, routing information, safety information, and informationrelating to post-build operations), information for customer use,information for commercial functions, information for consumer safety,information for security functions, and combinations thereof. Theinformation may be included in the ID-tag insert prior to being placedin the 3D object, or may be written to the ID-tag insert after theID-tag insert is placed in the 3D object. The format of the informationincluded in the ID-tag insert may vary depending on the type of ID-taginsert used, the scanning system used to read the information from theID-tag insert, and the purpose of the information. In one embodiment,the information included in the ID-tag insert is an alphanumeric codethat corresponds to one or more defined actions that will be performedon the 3D object after the build operation is complete. For example, thealphanumeric code may correspond to a set of defined instructions thatdesignate the post-build operations that will be performed on the 3Dobject (e.g., support structure removal and surface smoothingprocesses). In alternative embodiments, the ID-tag insert may includetextual information and/or computer instructions dictating how the 3Dobject will be handled after the build operation is complete, therebyallowing the ID-tag insert to be used with a variety of scanning systemswithout requiring defined alphanumeric codes.

Pursuant to step 14 of method 10, the data representation of the ID-taginsert is desirably generated at a location in the CAD model thatsubstantially preserves the structural integrity of the 3D object (e.g.,a central location within the CAD model), and that allows the ID-taginsert to communicate with one or more scanning systems. The datarepresentation of the ID-tag insert may also be generated at locationsin the CAD model that preserve or enhance other qualities of the 3Dobject (e.g., aesthetic and functional qualities). For thin-film, ID-taginserts, the data representations of the ID-tag inserts are alsodesirably oriented in a horizontal manner, thereby allowing thethin-film, ID-tag inserts to align with the layers of the 3D objects toform substantially flush working surfaces. As discussed below, thisallows the thin-film, ID-tag inserts to function as layers of the 3Dobjects, which increases the efficiencies of build operations with RP/RMsystems. Alternatively, crown inserts may be placed over the ID-taginserts to provide substantially planar top surfaces, as disclosed inU.S. patent application Ser. No. 12/006,955, entitled “Method forBuilding Three-Dimensional Objects Containing Embedded Inserts”.

After the data representation of the ID-tag insert is generated, thehost computer generates build sequence data for building the 3D objectfrom the CAD model (step 16). The build sequence data is a set ofinstructions that direct the RP/RM system to build the 3D object usingthe layer-based additive technique. The build sequence data also directswhen and how the ID-tag insert is placed in the 3D object during thebuild operation. In one embodiment, the host computer analyzes the CADmodel and generates the build sequence data using the techniquesdisclosed in U.S. patent application Ser. No. 12/006,955, entitled“Method for Building Three-Dimensional Objects Containing EmbeddedInserts”. The resulting build sequence data is then relayed to the RP/RMsystem for performing the build operation to fabricate the 3D object andany corresponding support structure.

During the build operation, the RP/RM system initially builds one ormore layers of the 3D object from a build material (step 18), and mayalso build one or more layers of a corresponding support structure. The3D object may be built with any suitable RP/RM system that fabricates 3Dobjects using a layer-based additive technique. Examples of suitableRP/RM systems include deposition-based systems (e.g., fused depositionmodeling and ink jetting systems), which deposit roads of build materialfrom a moveable deposition head to form the layer(s) of the 3D object,and energy-application systems (e.g., selective laser sintering,electron-beam melting, and stereolithographic systems), which emitenergy from a moveable energy source (e.g., a laser) to form thelayer(s) of the 3D object. In one embodiment, the RP/RM system is asystem that includes an automated insert-placement apparatus asdisclosed in U.S. patent application Ser. No. 12/006,947 entitled“System for Building Three-Dimensional Objects Containing EmbeddedInserts, and Methods of Use Thereof”.

After the initial layer(s) of the 3D object are built, the ID-tag insertis then placed on at least a portion of the built layer(s) of the 3Dobject (step 20). The ID-tag insert may be placed on the built layer(s)manually or in an automated manner. The RP/RM system then builds one ormore additional layers of the 3D object on top of the previously builtlayer(s) of the 3D object and on top of the ID-tag insert (step 22) tocomplete the build operation. The RP/RM system may also build one ormore layers of the corresponding support structure. When the buildoperation is complete, the 3D object dimensionally corresponds to thereceived CAD model, and includes the ID-tag insert at least partiallyembedded within the 3D object.

In one embodiment, the ID-tag insert is fully embedded within the 3Dobject. This embodiment is beneficial because a fully embedded ID-taginsert is not visible outside of the 3D object, thereby preserving theaesthetic qualities of the 3D object. Additionally, a fully embeddedID-tag insert is not affected by post-build operations that modify theexterior surface of the 3D object, such as support structure removal andsurface smoothing processes. As a result, the ID-tag insert may be usedwhile the 3D object undergoes a variety of different surface-modifyingoperations.

After the build operation is complete, the 3D object is removed from theRP/RM system and may undergo one or more post-build operations,packaging, and shipping. Additionally, as discussed above, in oneembodiment, information may be written to the ID-tag insert after theID-tag insert is placed in the 3D object. In this embodiment, theinformation may be written to the ID-tag at one or more points in timeafter the build operation is complete, where the ID-tag insert is atleast partially embedded within the 3D object. For example, informationmay be written to the ID-tag after the build operation is complete andprior to shipment to the customer. Alternatively, the ID-tag may remainunwritten until received by a customer, thereby allowing the customer tocontrol the information that is written to and read from the ID-taginsert. Furthermore, the ID-tag insert may rewritable to allow theinformation relating to the 3D object be updated and/or replaced.

At one or more points in time after the build operation is complete andthe ID-tag insert includes information relating to the 3D object, theinformation in the ID-tag insert is read by passing the 3D object by oneor more scanning systems (step 24). The type of scanning system(s) usedmay vary depending on the type of ID-tag insert used, and are desirablycapable of reading information from the ID-tag insert while the ID-taginsert is embedded within the 3D object. For example, for a passive RFIDtag insert fully embedded within a 3D object, the information may beread from the passive RFID tag insert with a radio-frequency (RF)transmitter/receiver that transmits an RF signal through the 3D object,to the passive RFID tag insert embedded within the 3D object. The RFsignal induces a small electrical current in an antenna of the passiveRFID tag insert, thereby providing power for an integrated circuit ofthe RFID tag insert to transmit the information back to the RFtransmitter/receiver. In alternative embodiments, one or more scanningsystems may be retained within the RP/RM system, thereby allowing thescanning system(s) to readily read the information from the ID-taginsert after the build operation is complete.

The information read from the ID-tag insert may provide instructions anddetails relating to the 3D object and/or relating to one or more actionsto perform on the 3D object (e.g., by the manufacturer and/or by thecustomer). In one embodiment, the information read from the ID-taginsert provides instructions for handling the 3D object after the buildoperation is complete. For example, the ID-tag insert may includerouting information for directing where the 3D object is to betransported after the build operation is complete, and for tracking the3D object during transit. This information is particularly suitable forrapid manufacturing applications, where large numbers of buildoperations are being performed. The ID-tag inserts accordingly alloweach 3D object to be accurately routed and tracked to the appropriatelocation, thereby reducing the risk of misdirecting one or more of thebuilt 3D objects.

The ID-tag insert may also include identification information for the 3Dobject, which allows the manufacturer to readily identify the customer,batch and lot numbers, purchase information, job queue orders, and othersimilar types of identification details. Such information furtherassists the manufacturer in routing and tracking the 3D object after thebuild operation is complete.

In addition to routing and identification information, the ID-tag insertmay also include information relating to physical handling requirementsfor the 3D object. For example, if the 3D object contains fragileportions that could be damaged during transit, the ID-tag insert mayprovide special handling requirements to ensure that the fragileportions remain intact. This is particularly beneficial for 3D objectshaving fragile portions that are difficult to visually recognize (e.g.,hollow interior cavities).

The ID-tag insert may also include information relating to safetyrequirements for handling the 3D object. This is beneficial for 3Dobjects built with materials that may be skin irritants, or that may beotherwise hazardous to handle. In one embodiment, the read informationprovides a material data safety sheet (MSDS), or similar information(e.g., lot, batch, and container information), for the build materialsused to form the 3D object and corresponding support structure. Thisallows the manufacturer to readily identify whether safety precautionsare required before handling the 3D object.

Furthermore, the ID-tag insert may include information relating to oneor more post-build operations to be performed on the 3D object, such assupport structure removal, surface smoothing processes, coolingoperations, cleaning operations, machining, benching, painting,packaging, and combinations thereof. This allows the manufacturer toreadily identify which post-build operations are required before the 3Dobject may be shipped to the customer. Such information may also includerouting information that identifies which post-build operation stationthe 3D object will be transported to, and information relating toprocessing parameters for the given post-build operation.

Examples of particularly suitable post-build operation informationincludes information relating to support structure removal, surfacesmoothing processes, and combinations thereof. For example, the readinformation may identify that the 3D object has a water-soluble supportstructure that needs removed, and may provide the location and job queueof an appropriate support removal station. This embodiment is beneficialbecause it may be difficult for the manufacturer to visually identify agiven 3D object prior to the removal of the support structure. Moreover,the information read from the ID-tag insert may also identify theprocessing parameters for the support structure removal, such astemperature requirements, circulation routines, handling limitations,and pH levels.

With respect to surface smoothing processes, the read information mayidentify that the 3D object requires a surface smoothing process, andmay provide the location and job queue of an appropriate surfacesmoothing station. Examples of suitable surface smoothing processes thatmay be identified with the information from the ID-tag insert includevapor smoothing processes as disclosed in Priedeman Jr., et al., U.S.Patent Application Publication No. 2005/0173838, entitled “SmoothingMethod for Layered Deposition Modeling”, and surface-treatment processesas disclosed in Zinniel, U.S. patent application Ser. No. 11/652,876,entitled “Surface-Treatment Method for Rapid-ManufacturedThree-Dimensional Objects”. The read information may also identify theprocessing parameters for the surface smoothing process, such assmoothing solvents, smoothing temperatures and durations, and safetyrequirements.

The ID-tag insert may also include information relating to a variety ofadditional manufacturing steps in an overall manufacturing process. Inone embodiment, method 10 may be a single step of multiple steps in amanufacturing process (e.g., a digital manufacturing process). As such,the information retained by the ID-tag insert may be used to assist inperforming the subsequent steps in the manufacturing process. Forexample, the ID-tag insert may provide tracking and processinginstructions for a variety of subsequent manufacturing steps, such aspainting, machining, gluing, annealing, metrology, stressing, plating,and combinations thereof.

The ID-tag insert may also include information that allows the customerto identify the 3D object. A common practice in product development isto build multiple 3D objects with RP/RM systems, where each of the 3Dobjects has a different design and/or physical property. This allows thedeveloper to test each of the 3D objects to identify the optimal designsand physical properties. However, it may be difficult to visuallydistinguish the differences in the designs and physical properties amongthe built 3D objects. Thus, the developer may use a scanning system toread the information contained in the ID-tag inserts, thereby allowingthe developer to identify the particular designs and physical propertiesfor each of the 3D objects.

The ID-tag may also include information relating to a variety ofcommercial, safety, and/or security functions, such as product tracking,transportation tracking, aviation security, inventory tracking, theftdetection, and the like. For example, the ID-tag may be used forshoplifting prevention in a store by setting off an alarm if a scannerlocated at an entrance of the store reads information from the ID-taginsert embedded in the 3D object. Accordingly, the ID-tag insertsembedded in the 3D objects may be used with many differentinformation-reading systems.

After the information is read from the ID-tag insert, one or moreactions may be performed based at least in part on the read information(step 26). For example, the manufacturer may read the information fromthe ID-tag insert, and then perform one or more actions on the 3D objectbased at least in part on the read information to fulfill customerorders. As discussed above, the action(s) may include identifying the 3Dobject (e.g., identifying the customer and batch/lot numbers), routingand tracking the 3D object after the build operation is complete,performing special handling actions to reduce the risk of damaging the3D object, taking safety measures to reduce the risk of injury whilehandling the 3D object, performing post-build operations (e.g., supportstructure removal and surface smoothing processes), and combinationsthereof. Accordingly, embedding the ID-tag insert in the 3D objectduring the build operation allows the required action(s) to be takenafter the build operation is complete. As discussed above, this isparticularly suitable for rapid manufacturing applications, and allowsthe manufacturer to readily track each of the numerous 3D objects, andto obtain required information for performing post-build operations.

An additional benefit of the above-discussed method 10 is that fullyembedded ID-tag inserts, which are not visually observable to acustomer, are not required to be removed after the action(s) arecomplete. Thus, in contrast to identification markings locatedexternally to the 3D object (e.g., on the support structures), theID-tag inserts may remain fully embedded within the 3D objects, and maycontinue to provide information even after the post-build operations arecomplete and the 3D object is packaged for shipping.

While the above discussion of method 10 refers to the use of a singleID-tag insert embedded within a 3D object, method 10 is also suitablefor building a 3D object containing multiple ID-tag inserts, where themultiple ID-tag inserts provide information for performing a variety ofaction(s). The multiple ID-tag inserts may be placed on the same ordifferent layers of the 3D object during the build operation. Thisembodiment is beneficial for pre-programmed ID-tag inserts, where eachID-tag insert placed in the 3D object may be pre-programmed to provide aspecific type of information. For example, a first type of ID-tag insertmay provide instructions for removing a support, and second type ofID-tag insert may provide instructions for performing a surfacesmoothing process. The pre-programmed ID-tag inserts may then be placedwithin 3D objects that require those particular post-build operations,and omitted from 3D objects that do not require those particularpost-build operations. The scanning system(s) may then read theinformation from each embedded ID-tag insert to identify whichpost-build operations are required for each of the 3D objects.

FIGS. 2A-2C, 3A-3C, 4A-4C, 5, and 6 are illustrations of suitabletechniques for building 3D objects containing embedded ID-tag inserts,pursuant to steps 18-22 of method 10 (shown in FIG. 1). FIGS. 2A-2C areschematic views of 3D object 28 being built on substrate platform 30 ofan RP/RM system (not shown), which illustrate a horizontal placementtechnique. As shown in FIG. 2A, pursuant to step 18 of method 10, theRP/RM system initially forms support layers 32 and build layers 34 in ahorizontal x-y plane on substrate platform 30. The horizontal x-y planeis a plane defined by an x-axis and a y-axis (not shown in FIG. 2A),where the x-axis, the y-axis, and the z-axis are orthogonal to eachother. As used herein, the term “axis” refers to a coordinate axis of aspatial coordinate system (e.g., a Cartesian coordinate system). Thethicknesses of support layers 32 and build layers 34 are exaggerated forease of discussion.

In the current example, support layers 32 are formed to assist theremoval of 3D object 28 from substrate platform 30 after the buildoperation is complete. Build layers 34 are a first set of layers of 3Dobject 28, and are formed up to the point where the ID-tag insert (notshown in FIG. 2A) will be placed. This is desirable for deposition-basedRP/RM systems to reduce the risk of collisions between the depositionhead and the placed ID-tag insert during the build operation.Accordingly, build layers 34 define pocket 36, which is an unfilledregion in build layers 34 that desirably corresponds to the dimensionsof the ID-tag insert. The horizontal arrangement of pocket 36 allows theID-tag insert to placed horizontally in pocket 36, which is beneficialfor use with thin-film, ID-tag inserts, and is also suitable for usewith pill-form ID-tag inserts.

As shown in FIG. 2B, after build layers 34 are formed, ID-tag insert 38is placed in pocket 36, manually or in an automated manner, pursuant tostep 20 of method 10. The arrangement of pocket 36 in the horizontal x-yplane allows ID-tag insert 38 to be horizontally oriented when placed inpocket 36. This allows ID-tag insert 38 to align with the top layer ofbuild layers 34, thereby providing a substantially flush surface betweenID-tag insert 38 and the top layer of build layers 34. The substantiallyflush surface correspondingly provides a substantially planar workingsurface for the formation of subsequent layers.

As shown in FIG. 2C, after ID-tag insert 38 is placed in pocket 36, theRP/RM system then forms build layers 40 of 3D object 28 on top of buildlayers 34 and on top of ID-tag insert 38. Build layers 40 are a secondset of layers of 3D object 28, formed pursuant to step 22 of method 10,which complete the build operation for 3D object 28. After the buildoperation is complete, ID-tag insert 38 is centrally located within 3Dobject 28, which substantially preserves the structural integrity of 3Dobject 28. At this point, 3D object 28 may be removed from the RP/RMsystem and one or more scanning systems may read the information fromID-tag insert 38 (pursuant to step 24 of method 10). As discussed above,in one embodiment, the information may be written to ID-tag insert 38after ID-tag insert 38 is placed in 3D object 28. In this embodiment,the information may be written to ID-tag 38 at one or more points intime after the build operation is complete, and the written informationmay be subsequently read, pursuant to step 24 of method 10. One or moreactions may then be performed based at least in part on the readinformation, such as one or more post-build operations (pursuant to step26 of method 10). As further shown in FIG. 2C, the central location ofID-tag insert 38 fully embeds ID-tag insert 38 within 3D object 28. Thisis beneficial for preserving the aesthetic qualities of 3D object 28,and allows 3D object 28 to undergo post-build, surface-modifyingoperations (e.g., support structure removal and surface smoothingprocesses) without adversely affecting ID-tag insert 38.

FIGS. 3A-3C are schematic views of 3D object 42 being built on substrateplatform 44 of an RP/RM system (not shown), which illustrate a verticalplacement technique. As shown in FIG. 3A, pursuant to step 18 of method10, the RP/RM system initially forms support layers 46 and build layers48 in a horizontal x-y plane on substrate platform 44. The thicknessesof support layers 46 and build layers 48 are exaggerated for ease ofdiscussion. Build layers 48 are a first set of layers of 3D object 42,and the arrangement of build layers 48 define cavity 50 and pocket 52.Cavity 50 is an unfilled region in 3D object 42 that prevents an ID-taginsert (not shown in FIG. 3A) from being centrally located within 3Dobject 42.

As discussed above, the ID-tag inserts are desirably placed at locationsthat substantially preserve the structural integrity the 3D objects.Additionally, for thin-film, ID-tag inserts, the ID-tag inserts are alsodesirably oriented horizontally, thereby allowing the thin-film, ID-taginserts to align with the layers of the 3D objects. However, in theexample shown in FIG. 3A, the geometry of 3D object 42 is not conducivefor the placement of a horizontally-oriented ID-tag insert. As shown, 3Dobject 42 includes wall portions 42 a and 42 b, and base portion 42 c,where wall portions 42 a and 42 b are vertical walls and base portion 42c is a horizontal base interconnecting wall portions 42 a and 42 b. AnID-tag insert having dimensions corresponding to pocket 52 does not fithorizontally within wall portion 42 a or wall portion 42 b. Furthermore,base portion 42 c is not thick enough along the z-axis to retain ahorizontally-placed ID-tag insert without reducing the structuralintegrity 3D object 42. Accordingly, to substantially preserve thestructural integrity of 3D object 42, the ID-tag insert may bevertically oriented along the z-axis and placed within wall portion 42 aat pocket 52. Pocket 52 is accordingly an unfilled region in buildlayers 48 that desirably corresponds to the dimensions of the ID-taginsert.

As shown in FIG. 3B, after build layers 48 are formed, ID-tag insert 54is placed vertically within pocket 52, manually or in an automatedmanner, pursuant to step 20 of method 10. The placement of ID-tag insert54 in pocket 52 desirably provides a substantially flush surface betweenthe top edge of ID-tag insert 54 and the top layer of build layers 48.This correspondingly provides a substantially planar working surface forthe formation of subsequent layers.

As shown in FIG. 3C, after ID-tag insert 54 is placed in pocket 52, theRP/RM system then forms build layers 56 of 3D object 42 on top of buildlayers 48 and on top of ID-tag insert 54. Build layers 56 are a secondset of layers of 3D object 42, formed pursuant to step 22 of method 10,which complete the build operation for 3D object 42. After the buildoperation is complete, 3D object 42 may be removed from the RP/RM systemand one or more scanning systems may read the information from ID-taginsert 54 (pursuant to step 24 of method 10). As discussed above, in oneembodiment, the information may be written to ID-tag insert 54 afterID-tag insert 54 is placed in 3D object 42. In this embodiment, theinformation may be written to ID-tag 54 at one or more points in timeafter the build operation is complete, and the written information maybe subsequently read, pursuant to step 24 of method 10. One or moreactions may then be performed based at least in part on the readinformation, such as one or more post-build operations (pursuant to step26 of method 10). As further shown in FIG. 3C, ID-tag insert 54 is fullyembedded within wall portion 42 a of 3D object 42. This is alsobeneficial for preserving the aesthetic qualities of 3D object 42, andallows 3D object 42 to undergo post-build, surface-modifying operations(e.g., support structure removal and surface smoothing processes)without adversely affecting ID-tag insert 54.

FIGS. 4A-4C are schematic views of 3D object 58 being built on substrateplatform 60 of an RP/RM system (not shown), which illustrate anear-vertical placement technique. The near-vertical placement techniqueis a modification to the vertical placement technique discussed above,and is suitable for situations where an ID-tag insert is not capable offitting horizontally or vertically within a 3D object (e.g., 3D object58) without reducing the structural integrity of the 3D object. As shownin FIG. 4A, pursuant to step 18 of method 10, the RP/RM system initiallyforms support layers 62 and build layers 64 in a horizontal x-y plane onsubstrate platform 60. The thicknesses of support layers 62 and buildlayers 64 are exaggerated for ease of discussion.

Build layers 64 are a first set of layers of 3D object 58, and thearrangement of build layers 64 define cavity 66 and pocket 68. Cavity 66is an unfilled region in 3D object 58 that prevents an ID-tag insert(not shown in FIG. 4A) from being placed in a central location of 3Dobject 58. As discussed above for 3D object 58 (shown in FIGS. 3A-3C),if the ID-tag insert cannot be placed horizontally in 3D object 58without reducing the structural integrity of 3D object 58, a verticalorientation may potentially be used. However, for 3D object 58, anID-tag insert having a length corresponding to the length of pocket 68would not fit vertically within the wall portion of 3D object 58(referred to as wall portion 58 a) without reducing the structuralintegrity of 3D object 58.

As shown in FIG. 4A, to accommodate the placement of an ID-tag insertwithin 3D object 58, while also substantially preserving the structuralintegrity of 3D object 58, pocket 68 is oriented at angle α from thevertical z-axis. Angle α desirably provides a length for pocket 68 thatallows an ID-tag insert to be fully placed within pocket 68, and thatalso substantially preserves the structural integrity of 3D object 58.Examples of suitable angles α for pocket 68 range from zero degrees(i.e., vertical) to less than about 45 degrees, with particularlysuitable angles α ranging from zero degrees to less than about 30degrees.

As shown in FIG. 4B, after build layers 64 are formed, ID-tag insert 70is placed within pocket 68, manually or in an automated manner, pursuantto step 20 of method 10. This positions ID-tag insert 70 within wallportion 58 a at angle α relative to the z-axis, which desirably providesa substantially flush surface between the top edge of ID-tag insert 70and the top layer of build layers 64. This provides a substantiallyplanar working surface for the formation of subsequent layers.

As shown in FIG. 4C, after ID-tag insert 70 is placed in pocket 68, theRP/RM system then forms build layers 72 of 3D object 58 on top of buildlayers 64 and on top of ID-tag insert 70. Build layers 72 are a secondset of layers of 3D object 58, formed pursuant to step 22 of method 10,which complete the build operation for 3D object 58. After the buildoperation is complete, 3D object 58 may be removed from the RP/RM systemand one or more scanning systems may read the information from ID-taginsert 70 (pursuant to step 24 of method 10). As discussed above, in oneembodiment, the information may be written to ID-tag insert 70 afterID-tag insert 70 is placed in 3D object 58. In this embodiment, theinformation may be written to ID-tag 70 at one or more points in timeafter the build operation is complete, and the written information maybe subsequently read, pursuant to step 24 of method 10. One or moreactions may then be performed based at least in part on the readinformation, such as one or more post-build operations (pursuant to step26 of method 10). As shown in FIG. 4C, ID-tag insert 70 is fullyembedded within wall portion 58 a of 3D object 58. This is alsobeneficial for preserving the aesthetic qualities of 3D object 58, andallows 3D object 58 to undergo post-build, surface-modifying operations(e.g., support structure removal and surface smoothing processes)without adversely affecting ID-tag insert 70.

FIG. 5 is a top perspective view of 3D object 74, which is built with anRP/RM system pursuant to steps 18-22 of method 10 (shown in FIG. 1), andillustrates a bent-vertical placement technique. The bent-verticalplacement technique is an additional modification to the verticalplacement technique discussed above, and is suitable for use withflexible ID-tag inserts and 3D objects having conical geometries (e.g.,3D object 74). As shown, 3D object 74 includes curved pocket 76 andID-tag insert 78, where ID-tag insert 78 is a flexible, thin-film,ID-tag insert that is fully embedded within 3D object 74 at curvedpocket 76.

The conical geometry of 3D object 74 prevents ID-tag insert 78 frombeing placed within curved pocket 76 in a planar orientation. Thus,during the build operation, curved pocket 76 is formed in the buildlayers of 3D object 74, and ID-tag insert 78 is then biased to match thedimensions of curved pocket 76. The biased ID-tag insert 78 is theninserted into curved pocket 76. The remaining build layers of 3D object74 are then formed to complete the build operation. The bent-verticalplacement technique allows ID-tag inserts (e.g., ID-tag insert 78) to befully embedded within 3D objects having conical geometries (e.g., 3Dobject 74), thereby preserving the aesthetic qualities of the 3Dobjects, and allowing the 3D objects to undergo post-build,surface-modifying operations without adversely affecting ID-tag insert70.

FIG. 6 is a bottom perspective view of 3D object 80, which is built withan RP/RM system pursuant to steps 18-22 of method 10 (shown in FIG. 1),and includes ID-tag insert 82 partially embedded within 3D object 80. Asshown, ID-tag insert 82 is a break-away ID-tag insert that includesembedded portion 84 (shown with hidden lines), tag portion 86, andperforation 88, where embedded portion 84 and tag portion 86 areconnected at perforation 88. This embodiment is beneficial for use with3D objects (e.g., 3D object 80) that are not large enough to retainfully embedded ID-tag inserts (e.g., ID-tag insert 82). In thisembodiment, tag portion 86 is the portion of ID-tag insert 82 thatincludes the readable information for use after the build operation iscomplete. As such, after the build operation is complete, one or morescanning systems are used to read the information from tag portion 86(pursuant to step 24 of method 10), and the read information is used toperform one or more post-build actions on 3D object 80 (pursuant to step26 of method 10). After the post-build action(s) are complete, tagportion 86 may be removed from embedded portion 86 by tearing ID-taginsert 82 at perforation 88. Tag portion 86 may then be discarded,leaving little or no impact on the surface quality of 3D object 80.

ID-tag inserts suitable for use with method 10 may be provided in avariety of geometries. As discussed above, the ID-tag inserts may beprovided as thin-film inserts, pill-shaped inserts, flexible tapeinserts, bendable inserts, and break-away inserts. Furthermore, theID-tag inserts may also have variable geometries, such as ID-tag insertsthat are cut-to-size, bent, folded, torqued, stretched, tapped, sized,or otherwise modified from stock material shapes to the shape taken bythe placed insert. For example, a RFID tag may be conically bent toconform to the interior rim of a smoke detector shell (as discussedabove for ID-tag insert 78, shown in FIG. 5), or a reinforcing wiremight be cut and bent in a serpentine system to attain the shape takenby the placed insert. In one embodiment, the intended geometry may bedefined by a CAD part designer, and information relating to the intendedgeometry may be transferred with the insert-placement location anddescription as part of the CAD model. Additional information that theRP/RM system might require to manipulate the insert (e.g., bendingradius and wire tension) may also be supplied.

As discussed above, method 10 (shown in FIG. 1) and the suitabletechniques for use in placing the ID-tag inserts in the 3D objects allowa variety of actions to be performed on the 3D objects after the buildoperations are complete. This increases efficiencies in the productionof 3D objects with RP/RM systems, particularly in rapid manufacturingapplications, thereby allowing manufacturers to meet individual customerschedules and design requirements. Although the present invention hasbeen described with reference to preferred embodiments, workers skilledin the art will recognize that changes may be made in form and detailwithout departing from the spirit and scope of the invention.

The invention claimed is:
 1. A method for building a three-dimensionalobject containing an identification-tag insert with an additivemanufacturing system in a layer by layer manner, the method comprising:performing a build operation to form layers of the three-dimensionalobject using a layer-based additive technique that utilizes build paths;placing the identification-tag insert on at least a portion of thelayers during the build operation, thereby at least partially embeddingthe identification-tag insert in the three-dimensional object; andreading information from the identification-tag insert while theidentification-tag insert is at least partially embedded within thethree-dimensional object.
 2. The method of claim 1, wherein theidentification-tag insert tag is fully embedded within thethree-dimensional object.
 3. The method of claim 1, wherein theidentification-tag insert comprises a radio-frequency identificationtag.
 4. The method of claim 1, further comprising performing at leastone surface-modifying operation on the three-dimensional object.
 5. Themethod of claim 4, wherein the at least one surface-modifying operationis selected from the group consisting of support structure removal,surface smoothing processes, and combinations thereof.
 6. The method ofclaim 1, wherein the identification-tag insert is placed on at least aportion of the layers in a horizontal orientation.
 7. The method ofclaim 1, wherein the identification-tag insert is placed on at least aportion of the layers at an angle from a vertical axis that ranges fromzero degrees to 45 degrees.
 8. The method of claim 1, further comprisingwriting the information to the identification-tag insert while theidentification-tag insert is at least partially embedded within thethree-dimensional object.
 9. A method for building a three-dimensionalobject containing an identification-tag insert with an additivemanufacturing system in a layer by layer manner, the method comprising:forming a plurality of layers of the three-dimensional object using alayer-based additive technique with the additive manufacturing systemthat utilizes tool paths; placing at least one identification-tag insertat least one of the plurality of formed layers, thereby at leastpartially embedding the at least one identification-tag insert in thethree-dimensional object; reading information from the at least oneidentification-tag insert while the at least one identification-taginsert is at least partially embedded within the three-dimensionalobject; and performing at least one action on the three-dimensionalobject based at least in part on the read information wherein the atleast one action comprises at least one post-build operation selectedfrom the group consisting of support structure removal, surfacesmoothing processes, cooling operations, cleaning operations, machining,benching, painting, packaging, and combinations thereof.
 10. The methodof claim 9, wherein the at least one identification-tag insert tag isfully embedded within the three-dimensional object.
 11. The method ofclaim 9, wherein the at least one identification-tag insert comprises atleast one radio-frequency identification tag.
 12. The method of claim 9,further comprising generating a data representation of the at least oneidentification-tag insert in a computer-aided design model of thethree-dimensional object.
 13. The method of claim 9, wherein the atleast one identification-tag insert is placed on at least a portion ofthe layers in a horizontal orientation.
 14. A method for building athree-dimensional object containing an identification-tag insert with anadditive manufacturing system in a layer by layer manner, the methodcomprising: forming a first set of layers of the three-dimensionalobject using a layer-based additive technique that utilizes tool paths;placing the identification-tag insert on at least a first portion of thefirst set of layers; forming a second set of layers of thethree-dimensional object on at least a second portion of the first setof layers and on at least a portion of the identification-tag insertusing the layer-based additive technique such that theidentification-tag insert is at least partially embedded between thefirst set of layers and the second set of layers; reading informationfrom the identification-tag insert after forming the second set oflayers; and performing at least one post-build operation on thethree-dimensional object based at least in part on the read informationwherein the at least one action comprises at least one post-buildoperation selected from the group consisting of support structureremoval, surface smoothing processes, cooling operations, cleaningoperations, machining, benching, painting, packaging, and combinationsthereof.
 15. The method of claim 14, wherein the at least oneidentification-tag insert tag is fully embedded between the first set oflayers and the second set of layers.
 16. The method of claim 14, whereinthe at least one identification-tag insert comprises at least oneradio-frequency identification tag.
 17. The method of claim 14, furthercomprising: receiving a computer-aided design model of thethree-dimensional object; and generating a data representation of theidentification-tag insert in the computer-aided design model.
 18. Themethod of claim 14, wherein forming a first set of layers of thethree-dimensional object comprises forming an unfilled region havingdimensions substantially corresponding to dimensions of theidentification-tag insert, and wherein placing the identification-taginsert on at least the first portion of the first set of layerscomprises placing the identification-tag insert in the unfilled region.